EAA00002

FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha motor-
cycle prior to delivery to the customer. Since some external parts of the motorcycle have been removed at
the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should
be noted that the assembled motorcycle should be thoroughly cleaned, inspected, and adjusted prior to
delivery to the customer.

EAA00005

NOTICE
The service specifications given in this assembly manual are based on the model as manufactured.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will
appear in future editions of this manual where applicable.
The procedures below are described in the order that the procedures are carried out correctly and com-
pletely. Failure to do so can result in poor performance and possible harm to the motorcycle and/or rider.

CONCERNING CRATE DAMAGE:

Follow the instructions in the Dealer Warranty Handbook, Procedure Section.

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!

WARNING Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander, or a person checking or repairing the motorcycle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

EAA00001

FZ6-SS
FZ6-SSC
ASSEMBLY MANUAL
E2003 by Yamaha Motor Corporation,
U.S.A. First Edition, November 2003
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11666-17-50
 EAA00008
(1) (2)
SYMBOLS USED IN THE
ASSEMBLY MANUAL
In order to simplify descriptions in this as-
sembly manual, the following symbols are
used:
(1): Coat with lithium-soap-based grease.
(3) (4) (2): Tighten to 10 Nm.
(10 Nm = 1.0 mSkg, 7.2 ftSlb)
(3): Towards the front of the motorcycle
(4): Clearance required
(5): Install so that the arrow mark faces up-
ward.
(6): Apply motor oil.
(5) (6) (7): Made of rubber or plastics
(8):
A: Ref. No. (indicating the order of op-
erations.)
B: Part name
C: Quantity of parts per motorcycle
(7) D: Place where parts are held
V: Stored in plastic bag
C: Stored in carton box
S: Fixed inside the steel frame
and / or contained in the Styro-
foam tray (upper or lower)
*: Temporarily installed or secured
(8) E: Size or material of parts
d / D: Diameter of part
: Length of part

e.g., 5 = 5 mm (0.2 in)

 EAA00040

PREPARATION
To assemble the motorcycle correctly, sup-
plies (e.g. oils, greases, and shop rags) and
sufficient working space are required.

Workshop
The workshop where the motorcycle is as-
sembled should be clean, spacious, and
have a level floor.

Self-protection
Protect your eyes with suitable safety
glasses or goggles when using compressed
air, when grinding or when doing any opera-
tion which may cause particles to fly off.
Protect hands and feet by wearing safety
gloves or shoes.

EAA00050
(1) (2)
SYMBOLS USED ON
CRATE CARTON
(1) Contents of the transport package are
fragile, therefore the package must be
handled with care.
(2) Indicates correct upright position of the
(3) (4) transport package.
(3) Transport package must be kept away
from rain.
(4) Insertion of the forklift arms from this
side can cause damage.
(5) Lift arm inserting position.

If the forklift arms cannot be inserted under

the transport package in alignment with the
two yellow labels, adjust the arms so that
they are positioned evenly in relation to
these marks while taking care not to dam-
age the package contents.

(5) (5)
EAA00060

UNPACKING
1. Remove the frame cover (1).
NOTE:
To remove the frame cover, cut the vinyl
bands around the cover using a cutter or
scissors.

2. Remove the carton boxes (2) and (3).

Remove the front wheel (4).

3. Remove the packing frame bolts (5) and

upper handlebar holders (6).

4. Remove the bolts (7).

5. Remove the packing frames (8). (Lift up

and then move to the side.)
NOTE:
Remove the bolts while holding the frame.

NOTE:
Before starting the assembly, check for
damaged or missing parts. Check both the
parts contained in the carton boxes and on
the motorcycle for damage, scratches, and
other defects.

1
EAA00070

PARTS LOCATION
(1) Carton box 1.
(2) Carton box 2.
(3) Front tire.

2
7
EAA00080

(1) Carton box 1

1. Screws and special nuts (windshield)
2. Upper handlebar holders
3. Rivets
4. Screws
5. Bolts
6. Plugs
7. Nuts
8. Screws
9. Washers
10. Screws
11. Nuts
12. Bands
13. Inner panels
14. Windshield trims
15. Rear view mirrors
16. Windshield
17. Front fender
18. Owners manual

(2) Carton box 2

1. Handlebar
2. Gnip end (right)
3. Bolts (upper handlebar holders)
4. Front brake master cylinder bracket
5. Bolts (front brake master cylinder brack-
et)
6. Screws (left handlebar switch)
7. Collars

(3) Front tire

3
EAA00100

SETUP PROCEDURES
Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown.

4
 EAA00014
EAA00102

1. HANDLEBAR
A: Clean the right handlebar end.
Apply light coat grease.
B: Install the handlebar holders
with the arrow mark facing for-
ward.
CAUTION:
First tighten the bolts on the
front side, and then tighten the
bolts on the rear side.

C: Align the punch mark on the

1 Handlebar holders 2 V
handlebar with the top of the
2 Hexagon head bolt 4 V d = 8 (0.31), = 30 (1.18)
lower handlebar holders.
3 Plug 4 V
D: Tighten the bolts to specifica-
4 Handlebar 1 C tion.
Bolt:
23 Nm (2.3 mSkg, 17 ftSlb)

EAA00016
EAA00104

2. THROTTLE GRIP
A: Align the projection on the han-
dlebar switch with the hole in
the handlebar.
B: Tighten the bolt to specifica-
tion.
Bolt:
3.5 Nm (0.35 mSkg, 2.5 ftSlb)

C: Check the throttle grip for

smooth action.
1 Screw 1 d = 5 (0.20), = 45 (1.77) WARNING
2 Screw 1 d = 5 (0.20), = 20 (0.79) Proper cable routing is essen-
3 Grip end 1 V tial to assure safe motorcycle
operation.
Refer to CABLE ROUTING.

D: Tighten the grip end.

Grip end:
26 Nm (2.6 mSkg, 19 ftSlb)
EAA00020 NOTE:
EAA00108 Do not depress the brake lever
3. FRONT WHEEL when the calipers are off the brake
A: Clean the brake discs. discs.
B: Clean the front wheel axle.
F: Tighten the wheel axle to speci-
C: Clean the collar.
fication.
D:
WARNING Wheel axle:
Take care not to get grease on 72 Nm (7.2 mSkg, 52 ftSlb)
the brake discs or inner surface
CAUTION:
of the brake pads. If you do so,
clean using a rag dampened Before tightening the wheel axle
with a solvent. Foreign material pinch bolt, stroke the front forks
1 Front tire 1 S on the braking surface may several times to make sure of
2 Collar 2 V cause impaired braking action. proper fork operation.
3 Axle 1 G: Tighten the wheel axle pinch
E: Lift the front wheel and install
4 Hexagon head bolt 1 bolt to specification.
the front wheel axle. Be sure
the arrow on the tire is pointed Wheel axle pinch bolt:
in the rotating direction. 23 Nm (2.3 mSkg, 17 ftSlb)

5
 EAA00022
WARNING
EAA00110
Proper cable routing is essen-
4. FRONT FENDER tial to assure safe motorcycle
A: Tighten the front fender bolts to operation.
specification. Refer to CABLE ROUTING.
Bolt:
C: Clamp the front brake hose.
6 Nm (0.6 mSkg, 4.3 ftSlb)

B:
CAUTION:
Make sure the brake hose is
routed outside of the front fend-
er.
1 Front fender 1 S Be careful not to scratch the
2 Bolt 2 V d = 6 (0.24), = 22 (0.87) front fender with the front fork
3 Bolt 2 V d = 6 (0.24), = 25 (0.98) outer tube.
4 Collar 2 V d = 6 (0.24)

1 Bracket
2 Hexagon head bolt
3 Master cylinder
4 Brake light switch connector
EAA00032
Bolt:
EAA00120
10 Nm (1.0 mSkg, 7.2 ftSlb)
5. FRONT BRAKE MASTER
CYLINDER E: Connect the front brake light
A: Lubricate the pivoting parts of switch connector.
the brake lever. F: Check the brake lever for
smooth action.
Recommended lubricants:
WARNING
Yamaha cable lube or motor
Proper cable and hose routing
oil
is essential to assure safe mo-
B: Make sure that the UP mark torcycle operation.
with the bracket is pointed up- Refer to CABLE ROUTING.
ward.
1 V C: Align the punch mark on the
2 V d = 6 (0.24), = 20 (0.79) handlebar with the gap of the
1 master cylinder bracket.
2 D: Tighten the bolts in stages and
maintain an equal gap on each
side of the bracket to specifica-
tion.

EAA00035
EAA00123

6. HANDLEBAR SWITCH
A: Align the projection on the left
handlebar switch with the hole
in the handlebar.
WARNING
Proper cable routing is essen-
tial to assure safe motorcycle
operation.
Refer to CABLE ROUTING.

B: Tighten the bolts to specifica-

1 Bolt 1 V d = 5 (0.20), = 45 (1.77)
tion.
2 Bolt 1 V d = 5 (0.20), = 30 (1.18) Bolt:
3.5 Nm (0.35 mSkg, 2.5 ftSlb)

6

1 Clutch cable
2 Clutch switch lead coupler
EAA00049
EAA00137
7. CLUTCH CABLE
A: Lubricate the pivoting part of
the clutch lever.
Recommended lubricants:
Yamaha cable lube or motor
oil
B: To install the clutch cable, be
sure to proceed as follows:
a. Turn in the adjuster on the lever
holder until tight. Next, align the
1 slit in the adjuster and cable
1 socket with the slit in the lever
holder.
b. Insert the cable end into the le-
ver hole. Next, while pulling the
outer cable in the direction op-
posite to the lever, seat the out-
er cable into the cable socket.
NOTE:
Check the clutch lever for smooth
action.
Refer to ADJUSTMENTS AND
PREDELIVERY SERVICE.
C: Install the clutch switch lead
coupler.
WARNING
Proper cable routing is essen-
tial to assure safe motorcycle
operation.
Refer to CABLE ROUTING.

8. BAND
A: Clamp the left handlebar
switch lead.
B: Clamp the right handlebar
switch lead.
WARNING
Proper cable routing is essen-
tial to assure safe motorcycle
operation.
Refer to CABLE ROUTING.

1 Band 2 V

EAA00053
EAA00141

9. WINDSHIELD
CAUTION:
The windshield is made of an
acrylate resin. Take care so that
it is not scratched.

A: Tighten the bolt to specifica-

tion.
Bolt:
0.4 Nm (0.04 mSkg, 0.3 ftSlb)

1 Windshield 1 C
2 Special nut 5 V
3 Screw 5 V
4 Windshield trims 2 C

7
 10. REAR VIEW MIRRORS
A: Tighten the rear view mirrors
nuts.
Nut:
7 Nm (0.7 mSkg, 5.1 ftSlb)

1 Rear view mirror 2 C

2 NUT 4 V

11. INNER PANEL

NOTE:
Remove the seat and fuel tank.

A: Tighten the bolts to specifica-

tion.
Bolt:
1.3 Nm (0.13 mSkg, 0.9 ftSlb)

B: Tighten the bolts to specifica-

tion.
Bolt:
4.5 Nm (0.45 mSkg, 3.3 ftSlb)
1 Inner panel 2 C
2 Screw 2 V d = 6 (0.24), = 16 (0.63) C: Install the rivets.
3 Washer 2 V d = 6 (0.24)
4 Screw 2 V d = 5 (0.20), = 12 (0.47)
5 Rivet 2 V
6 Screw 2 d = 6 (0.24), = 16 (0.63)
7 Washer 2 d = 6 (0.24)

EAA00189

12. BATTERY
A: Install the battery.
NOTE:
Refer to ADJUSTMENTS AND
PREDELIVERY SERVICE.

B: Install the battery cover.

Bolt:
7 Nm (0.7 mSkg, 5.1 ftSlb)

C: First, connect the positive lead

(red lead) to the positive termi-
1 Battery 1 nal.
2 Battery cover 1 D: Second, connect the negative
3 Bolt 2 d = 6 (0.24), = 25 (0.98) lead (black lead) to the nega-
tive terminal.
4 Bolt 2 d = 6 (0.24), = 10 (0.39)
NOTE:
Refer to CABLE ROUTING.

NOTE:
Install the fuel tank and seat.
8
EAA00900

CABLE ROUTING
WARNING
Proper cable and lead routing are essential to insure safe motor-
cycle operation.

(1) Right handlebar switch lead

(2) Throttle cables
(3) Clutch cable
(4) Left handlebar switch lead
(5) Main switch lead
(6) Battery positive lead
(7) Battery cover
(8) Starter relay lead
(9) Battery negative lead
A Clamp the right and left handlebar switch leads to the handlebar.
Point the tip of the clamp downword in front of the handlebar.
B Pass the throttle cables through the wire guide. Route the right
handlebar switch lead by the outside of the wire guide.
C Route the main switch lead and immobilizer lead above the clutch
cable.
D Route the throttle cables above the stay 1.
E Hook the starter motor lead to the alternate pawls on the battery
cover.
F Route the starter relay lead outside of the main switch and immobi-
lizer lead.

9
EAA01100

ADJUSTMENTS AND PREDELIVERY

SERVICE
Perform the predelivery service in the order indicated by the letters.
Always follow the order as shown.

10
EAA01000
A. CHECKING AND CHARGING
THE BATTERY
NOTE:
The battery used in this motorcycle is a
maintenance free (MF) Valve Regulated
Lead Acid Battery, it has been pre-filled
with electrolyte at the factory so there is no
need to add fluid at any time.
1. Check:
Using a digital volt meter, the state of a dis-
charged MF battery can be checked by
measuring open-circuit voltage (the voltage
measured with the positive and negative
terminals being disconnected).
Open-circuit voltage
12.8 V or higher
Charging time
Charging is not necessary
EAA01009
B. CHECKING THE TIRE
PRESSURE
1. Check:
D tire pressure
Out of specification ! Adjust.
WARNING
D The tire pressure should only be
checked and regulated when the tire
temperature equals the ambient air
temperature.
D The tire pressure and the suspension
must be adjusted according to the to-
tal weight (including cargo, rider,
passenger, and accessories) and the
anticipated riding speed.
D Operation of an overloaded motor-
cycle could cause tire damage, an ac-
cident, or an injury.
NEVER OVERLOAD THE MOTOR-
CYCLE.
11
WARNING
D Do not attempt boost charging under
any circumstances.
D Battery electrolyte is poisonous and
dangerous, causing severe burns,
etc. It contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
Antidote: External-Flush with water. In-
ternal-Drink large quantities of water or
milk. Follow with milk of magnesia, beat-
en egg, or vegetable oil. Call physician
immediately.
Eyes: Flush with water for 15 minutes
and get prompt medical attention. Bat-
teries produce explosive gases. Keep
sparks, flame, cigarettes, etc., away.
Ventilate when charging or using in en-
closed space. Always shield eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHIL-
DREN.
CAUTION:
D If the voltage is lower than 12.8 V the
battery must be charged. If this is not
done, the life of the battery will be
shortened drastically. Refer to the
service manual for battery charging
instructions.
D Never remove the strip of caps, nor
add any water or electrolyte.
Basic weight:
With oil and full fuel tank
207 kg (456 lb) (except for CAL)
208 kg (458 lb) (for CAL)
Maximum load*
190 kg (419 lb) (except for CAL)
189 kg (417 lb) (for CAL)
Cold tire pressure
Up to 90 kg load*
Front
225 kPa (2.25 kgf / cm2, 33 psi)
Rear
250 kPa (2.5 kgf / cm2, 35.6 psi)
90kg X Maximum load*
Front
250 kPa (2.5 kgf / cm2, 35.6 psi)
Rear
290 kPa (2.9 kgf / cm2, 41.3 psi)
High speed riding
Front
225 kPa (2.25 kgf / cm2, 33 psi)
Rear
250 kPa (2.5 kgf / cm2, 35.6 psi)
* Load is the total weight of cargo, rider, pas-
senger, and accessories.
EAA01013
C. CHECKING THE ENGINE OIL
LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
D Place the motorcycle on a suitable stand.
D Make sure that the motorcycle is upright.
2. Let the engine idle for a few minutes, and
then turn it off.
3. Remove:
D dipstick
4. Check:
D engine oil level
The engine oil level should be between
the minimum level mark (a) and maxi-
mum level mark (b).
Below the minimum level mark ! Add
the recommended engine oil to the prop-
er level.
NOTE:
D Before checking the engine oil level, wait
a few minutes until the oil has settled.
D Do not screw the dipstick in when check-
ing the oil level.
Recommended oil
At 5_C (40_F) or higher A
Yamalube 4 (20W40) or
SAE 20W40 type SE motor oil
At 15_C (60_F) or lower B
Yamalube 4 (10W30) or
SAE 10W30 type SE motor oil
Quantity
Without oil filter cartridge replacement
2.5 L (2.20 Imp qt, 2.64 US qt)
CAUTION:
D Engine oil also lubricates the clutch
and the wrong oil types or additives
could cause clutch slippage. There-
fore, do not add any chemical addi-
tives.
D Do not allow foreign materials to en-
ter the crankcase.
NOTE:
API Service SE, SF and SG type or
equivanlent (e.g., SF-SE, SF-SE-CC,
SF-SE-SD)
5. Start the engine, warm it up for several
minutes, and then turn it off.
6. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a
few minutes until the oil has settled.
7. Install:
D dipstick

EAA01017 3. Start the engine, warm it up for several

D. CHECKING THE COOLANT minutes, and then turn it off.
LEVEL 4. Check:
1. Stand the motorcycle on a level surface. D coolant level
NOTE: NOTE:
D Place the motorcycle on a suitable Before checking the coolant level, wait a few
stand. minutes until it settles.
D Make sure that the motorcycle is upright.

2. Check:
D coolant level
The coolant level should be between the
maximum level mark (a) and minimum
level mark (b).
Below the minimum level mark ! Add
the recommended coolant to the proper
level.
CAUTION:
D Adding water instead of coolant low-
ers the antifreeze content of the cool-
ant. If water is used instead of cool-
ant, check and correct the antifreeze
concentration of the coolant.
D Use only distilled water. Soft water
may be used if distilled water is not
available.

12
EAA01020 3. Adjust:
E. ADJUSTING THE ENGINE D engine idling speed
IDLING SPEED a. Turn the throttle stop screw (1) in direc-
tion (a) or (b) until the specified engine
NOTE:
Prior to adjusting the engine idling speed, idling speed is obtained.
the throttle bodies synchronization should Direction (a)
be adjusted properly, the air filter should be Engine idling speed is increased.
clean, and the engine should have ade- Direction (b)
quate compression. Engine idling speed is decreased.
1. Start the engine and let it warm up for
several minutes.
2. Measure:
D engine idling speed
Out of specification ! Adjust.
Engine idling speed
1,250 X 1,350 r / min

EAA01022

F. ADJUSTING THE THROTTLE

CABLE FREE PLAY
NOTE:
Prior to adjusting throttle cable free play, the
engine idling speed should be adjusted.

1. Measure:
D throttle cable free play (a)
Out of specification ! Adjust.
Throttle cable free play (at the flange
of the throttle grip)
3 X 5 mm (0.12 X 0.20 in)

2. Adjust: WARNING
a. Loosen the locknut (1). After adjusting the throttle cable free
b. Turn the adjusting nut (2) in direction (a) play, turn the handlebar to the right and
or (b) until the specified throttle cable to the left to ensure that this does not
free play is obtained. cause the engine idling speed to change.
Direction (a)
Throttle cable free play is increased.
Direction (b)
Throttle cable free play is decreased.

c. Tighten the locknut.

13
EAA01023
WARNING
G. ADJUSTING THE FRONT After adjusting the brake lever position,
BRAKE make sure that the pin on the brake lever
1. Adjust: holder is firmly inserted in the hole in the
D brake lever position adjusting dial.
(distance (a) from the throttle grip to the
brake lever) CAUTION:
a. While pushing the brake lever forward, After adjusting the brake lever position,
turn the adjusting dial (1) until the brake make sure that there is no brake drag.
lever is in the desired position.
WARNING
NOTE:
A soft or spongy feeling in the brake le-
Be sure to align the setting on the adjusting
ver can indicate the presence of air in the
dial with the arrow mark (2) on the brake le-
brake system. Before the vehicle is oper-
ver holder.
ated, the air must be removed by bleed-
ing the brake system.
Position #1 Air in the brake system will considerably
Distance (a) is the largest. reduce braking performance and could
Position #5 result in loss of control and possibly an
Distance (b) is the smallest. accident. Therefore, check the brake
system and bleed if necessary.

EAA01027
WARNING
H. ADJUSTING THE REAR BRAKE After adjusting the brake pedal position,
1. Measure: make sure that the end of the adjusting
D brake pedal position (a) bolt (c) is visible through the hole (d).
(below the bottom of the footrest brack-
et) c. Tighten the locknut (1) to specification.
Out of specification ! Adjust.
Locknut
Brake pedal position (top of the footrest) 18 Nm (1.8 mSkg, 13 ftSlb)
25.8 mm (1.02 in)
WARNING
2. Adjust: A soft or spongy feeling in the brake ped-
D brake pedal position al can indicate the presence of air in the
a. Loosen the locknut (1). brake system. Before the vehicle is oper-
b. Turn the adjusting bolt (2) in direction (a) ated, the air must be removed by bleed-
or (b) until the specified brake pedal ing the brake system. Air in the brake
position is obtained. system will considerably reduce braking
Direction (a) performance and could result in loss of
control and possibly an accident. There-
Brake pedal is raised.
Direction (b) fore, check the brake system and bleed if
Brake pedal is lowered. necessary.

CAUTION:
After adjusting the brake pedal position,
make sure that there is no brake drag.

14
 EAA01032
A WARNING
I. CHECKING THE BRAKE FLUID D Use only designated brake fluid.
LEVEL Other brake fluids may cause the rub-
1. Stand the motorcycle on a level surface. er seals to deteriorate, causing leak-
NOTE: age and poor brake performance.
D Place the motorcycle on a suitable D Refill with the same type of brake
stand. fluid that is already in the system.
D Make sure that the motorcycle is upright. Mixing brake fluids may result in a
harmful chemical reaction, leading to
2. Check: poor brake performance.
B D brake fluid level D When refilling, be careful that water
Below the minimum level mark (a) ! does not enter the reservoir. Water
Add the recommended brake fluid to the will significantly lower the boiling
proper level. point of the brake fluid and could
Recommended brake fluid cause vapor lock.
DOT 4
CAUTION:
A Front brake Brake fluid may damage painted sur-
B Rear brake faces and plastic parts. Therefore, al-
ways clean up any split brake fluid im-
mediately.

NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure that the top of
the reservoir is level.

EAA01035 d. Place the other end of the hose into a

J. BLEEDING THE HYDRAULIC container.
BRAKE SYSTEM e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully de-
WARNING
press the brake pedal and hold it in posi-
Bleed the hydraulic brake system when-
tion.
ever:
g. Loosen the bleed screw.
D the system was disassembled,
This will release the tension and cause
D a brake hose was loosened or re-
the brake lever to contact the throttle grip
moved,
or the brake pedal to fully extend.
D the brake fluid level is very low,
h. Tighten the bleed screw and then re-
D brake operation is faulty.
lease the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
NOTE:
bubbles have disappeared from the
D Be careful not to spill any brake fluid or
brake fluid in the plastic hose.
allow the brake fluid reservoir to over-
j. Tighten the bleed screw to specification.
flow.
D When bleeding the hydraulic brake sys- Bleed screw
tem, make sure that there is always 6 Nm (0.6 mSkg, 4.3 ftSlb)
enough brake fluid before applying the
brake. Ignoring this precaution could al- k. Fill the reservoir to the proper level.
A Refer to CHECKING THE BRAKE
low air to enter the hydraulic brake sys-
tem, considerably lengthening the FLUID LEVEL.
bleeding procedure. WARNING
D If bleeding is difficult, it may be neces- After bleeding the hydraulic brake sys-
sary to let the brake fluid settle for a few tem, check the brake operation.
hours. Repeat the bleeding procedure
when the tiny bubbles in the hose have
disappeared.

1. Bleed:
B D hydraulic brake system
a. Add the recommended brake fluid to the
proper level.
b. Install the brake fluid reservoir dia-
phragm.
c. Connect a clear plastic hose (1) tightly to
the bleed screw (2).
A Front
B Rear

15
EAA01036 2. Adjust:
K. ADJUSTING THE CLUTCH D clutch cable free play
CABLE FREE PLAY Handlebar side
1. Measure: a. Turn the adjusting dial (1) in direction (b)
D clutch cable free play (a) or (c) until the specified clutch cable free
Out of specification ! Adjust. play is obtained.

Clutch cable free play (at the end of Direction (b)

the clutch lever) Clutch cable free play is increased.
10 X 15 mm (0.39 X 0.59 in) Direction (c)
Clutch cable free play is decreased.

EAA01050 NOTE:
L. ADJUSTING THE REAR SHOCK Adjust the spring preload with the special
ABSORBER ASSEMBLY wrench and extension bar included in the
WARNING owners tool kit.
Securely support the motorcycle so that a. Turn the adjusting ring (1) in direction (a)
there is no danger of it falling over. or (b).
b. Align the desired position on the adjust-
ing ring with the stopper (2).
Direction (a)
Spring preload
Spring preload is increased
CAUTION: (suspension is harder).
Never go beyond the maximum or mini- Direction (b)
mum adjustment positions. Spring preload is decreased
(suspension is softer).
1. Adjust:
D spring preload
Adjusting positions
Standard: 3
Minimum: 1
Maximum: 7

16
EAA01059 4. Loosen:
M. ADJUSTING THE DRIVE CHAIN D wheel axle nut (1)
SLACK 5. Adjust:
D drive chain slack
NOTE:
a. Loosen both locknuts (2).
The drive chain slack must be checked at
b. Turn both adjusting nuts (3) in direction
the tightest point on the chain.
(a) or (b) until the specified drive chain
CAUTION: slack is obtained.
A drive chain that is too tight will over- Direction (a)
load the engine and other vital parts, and Drive chain is tightened.
one that is too loose can skip and dam- Direction (b)
age the swingarm or cause an accident. Drive chain is loosened.
Therefore, keep the drive chain slack
within the specified limits. NOTE:
D To maintain the proper wheel alignment,
1. Stand the motorcycle on a level surface. adjust both sides evenly.
WARNING D Push the rear wheel forward to make
Securely support the motorcycle so that sure that there is no clearance between
there is no danger of it falling over. the swingarm end plates and the ends of
the swingarm.
NOTE:
Both wheels should be on the ground with- c. Tighten the wheel axle nut to specifica-
out a rider on the motorcycle. tion.

2. Rotate the rear wheel several times and
check the drive chain to locate its tight-
est point.
3. Measure:
D drive chain slack (a)
Out of specification ! Adjust.
Wheel axle nut
120 Nm (12 mSkg, 87 ftSlb)
d. Tighten the locknuts to specification.
Locknut
16 Nm (1.6 mSkg, 12 ftSlb)

Drive chain slack

45 X 55 mm (1.77 X 2.17 in)

EAA01062

N. ADJUSTING THE REAR BRAKE

LIGHT SWITCH
NOTE:
The rear brake light switch is operated by
the movement of the brake pedal.
The rear brake light switch is properly ad-
justed when the brake light comes on just
before the braking effect starts.

1. Check:
D rear brake light operation timing
Incorrect ! Adjust.
2. Adjust:
D rear brake light operation timing
a. Hold the main body (1) of the rear brake
light switch so that it does not rotate and
turn the adjusting nut (2) in direction (a)
or (b) until the rear brake light comes on
at the proper time.
Direction (a)
Brake light comes on sooner.
Direction (b)
Brake light comes on later.

17
EAA01065

O. ADJUSTING THE HEADLIGHT

BEAMS
The following procedure applies to both of
the headlights.
1. Remove:
D front cowlling inner panels
2. Adjust:
D headlight beam (vertically)
a. Turn the adjusting screw (1) in direction
(a) or (b).
Direction (a)
Headlight beam is raised.
Direction (b)
Headlight beam is lowered.

3. Adjust:
D headlight beam (horizontally)
a. Turn the adjusting screw (2) in direction
(a) or (b).
Direction (a)
Headlight beam moves to the left.
Direction (b)
Headlight beam moves to the right.

4. Install:
D front cowling inner panels.

EAA00185

P. ADJUSTING THE DIGITAL

CLOCK
Turn the key to ON.
To change the display to the clock mode,
push the SELECT button (3) for at least
one second.
To change the display back to the prior
mode, push the SELECT button (3).
1. Adjust:
D digital clock (1)

a. Push the SELECT button (3) and RE-

SET button (2) together for at least two
seconds.
b. When the hour digits start flashing, push
the RESET button (2) to set the hours.
c. Push the SELECT button (3), and the
minute digits will start flashing.
d. Push the RESET button (2) to set the
minutes.
e. Push the SELECT button (3) and then
release it to start the clock.

18
EAA10000

APPENDICES
SERVICE DATA
Engine idling speed:
1,250 X 1,350 r / min
Spark plug:
Type:
CR9EK (NGK)
Gap:
0.6 X 0.7 mm (0.0236 X 0.0276 in)
Fuel:
Recommended fuel:
Regular unleaded gasoline
Fuel tank capacity:
Total:
19.4 L (4.27 Imp gal, 5.13 US gal)
Valve clearance (cold):
IN:
0.13 X 0.20 mm (0.0051 X 0.0079 in)
EX:
0.23 X 0.30 mm (0.0091 X 0.0118 in)

Maximum load* 190 kg (419 lb)

(except for CAL)
189 kg (417 lb) (for CAL)

Tire pressure:
Up to 90 kg load*
Front:
225 kPa (2.25 kgf / cm2, 33 psi)
Rear:
250 kPa (2.5 kgf / cm2, 35.6 psi)
90 kg load X Maximum load*
Front:
250 kPa (2.5 kgf / cm2, 35.6 psi)
Rear:
290 kPa (2.9 kgf / cm2, 41.3 psi)
High-speed riding
Front:
225 kPa (2.25 kgf / cm2, 33 psi)
Rear:
250 kPa (2.5 kgf / cm2, 35.6 psi)
* Load is the total weight of cargo, rider,
passenger, and accessories.

EAA10100

STANDARD EQUIPMENT
1. Owners manual 1 pc.
2. Owners tool kit 1 pc.

EAA10200

OWNERS TOOL KIT

1. Owners tool bag 1 pc.
2. Wrench (10-12) 2 pc.
3. Wrench (22-24) 1 pc.
4. Special wrench 1 pc.
5. Extension bar 1 pc.
6. Spark plug wrench 1 pc.
7. Screwdriver grip 1 pc.
8. Screwdriver bit (Phillips-slotted) 1 pc.
9. Hexagon wrench (5) 1 pc.

19
 TIGHTENING TORQUES

Thread Tightening
Item
size Nm mSkg ftSlb
Engine:
Spark plug M10 18 1.8 13
Engine oil drain bolt M14 43 4.3 31
Chassis:
Upper bracket pinch blot M8 30 3.0 22
Steering stem nut M22 110 11 80
Upper bracket and upper handlebar holder M8 23 2.3 17
Under bracket pinch blot 30 3.0 22
Lower ring nut M25 See NOTE1
Front fork cap bolt M35 24 2.4 17
Damper rod assembly bolt M10 23 2.3 17
Pinch bolt (front wheel axle) M8 23 2.3 17
Front brake master cylinder and master cylinder bracket M6 10 1.0 7.2
Front brake master cylinder cap screw M4 2 0.2 1.4
Front brake hose union blot M10 30 3.0 22
Front brake hose holder and front fork M6 10 1.0 7.2
Front cowling stay and frame M8 33 3.3 24
Front cowling bracket and frame M6 7 0.7 5.1
Front fender and front fork M6 6 0.6 4.3
Clutch lever holder pinch bolt M6 11 1.1 8.0
Engine mount bolts (left of front side) M10 55 5.5 40
Engine mount bolts (left of rear side) M10 55 5.5 40
Engine mount bolts (right of front side) M10 55 5.5 40
Engine mount self locking nut (upper) M10 55 5.5 40
Engine mount self locking nut (lower) M10 55 5.5 40
Pivot shaft and frame M18 120 12 87
Rear shock absorber and frame M10 40 4.0 29
Rear shock absorber and rear arm M10 40 4.0 29
Seal guard and rear arm M6 7 0.7 5.1
Rear fender and rear arm M6 7 0.7 5.1
Rear brake hose holder and rear arm M6 7 0.7 5.1
Fuel tank bracket and frame M6 7 0.7 5.1
Fuel tank bracket and fuel tank M6 7 0.7 5.1
Fuel tank and rear frame M6 7 0.7 5.1
Fuel tank and fuel tank cap M5 6 0.6 4.3
Fuel pump and fuel tank M5 4 0.4 2.9
Ignition coil and battery box M6 7 0.7 5.1
Seat lock and frame M6 7 0.7 5.1
Rotor and mud guard M6 3 0.3 2.2
Licence plate light and flap M5 4 0.4 2.9
Rear reflector and flap M5 4 0.4 2.9
Flap and bracket 6 M6 7 0.7 5.1
Blacket 6 and rear frame M6 19 1.9 14
Seat handle and tail/brake right unit M6 3 0.3 2.2
Rear fender cover and seat handle M5 4 0.4 2.9
Seat handle bolt M8 23 2.3 17
Muffler and rear fender M6 7 0.7 5.1
Side cover and rear frame M6 10 1.0 7.2

20
 Thread Tightening
Item
size Nm mSkg ftSlb
Rear mud guard and rear frame M6 7 0.7 5.1
Engine stop switch and frame M4 2 0.2 1.4
Coolant reserver tank bracket and stay 1, 2 M6 10 1.0 7.2
Stay 1, 2 and frame M6 10 1.0 7.2
Coolant reserver tank bracket and coolant reserver tank M6 4 0.4 2.9
Front wheel axle shaft and bolt M18 72 7.2 52
Front wheel axle pinch bolt M8 23 2.3 17
Front brake caliper and front fork M10 40 4.0 29
Front brake disc and front wheel M6 18 1.8 13
Brake caliper bleed screw M7 6 0.6 4.3
Rear wheel axle nut M24 120 12 87
Rear brake disc and rear wheel M8 30 3.0 22
Rear brake caliper bolt front and rear brake caliper bracket M8 27 2.7 20
Rear brake caliper bolt rear and rear brake caliper bracket M8 22 2.2 16
Rear wheel sprocket and rear wheel drive hub M10 100 10 72
Chain adjusting bolt lock nut M8 16 1.6 12
Rear brake hose union bolt M10 30 3.0 22
Sidestand bolt lock nut M10 46 4.6 33
Sidestand bracket and frame M10 63 6.3 46
Sidestand switch screw M5 4 0.4 2.9
Footrest bracket and frame M8 30 3.0 22
Rear brake reserver tank and coolant reserver tank bracket M6 3 0.3 2.2
Rear master cylinder and footrest bracket M8 23 2.3 17
Mainstand and nut M10 73 7.3 53
Footrest and footrest bolt M8 10 1.0 7.2
Brake pedal and brake shaft M6 8 0.8 5.8

NOTE 1:
1. First, tighten the ring nut to approximately 52 Nm (5.2 mSkg, 38 ftSlb) with a torque wrench, then loosen
the ring nut completely.
2. Retighten the lower ring nut 18 Nm (1.8 mSkg, 13 ftSlb).

21
PRINTED IN USA